Method of making a pressure-sensitive adhesive fastener

Abstract

A pressure-sensitive adhesive fastener having a textured fastening surface so as to have a relatively high shear resistance and a desired peel resistance. The pressure-sensitive adhesive fastener comprises a backing web having bulbous surface aberrations projecting from a first surface of the backing web and a layer of pressure-sensitive adhesive coated over and bonded to at least a portion of the surface of the bulbous surface aberrations of the backing web. The present invention also relates to a fastening system using the pressure-sensitive adhesive fastener of the present invention.

What is claimed is: 
     
       1. A method for forming a textured pressure-sensitive adhesive fastener, said method comprising the steps of: (a) providing a backing web having a first surface and a second surface, the backing web having discrete, bulbous surface aberrations projecting from the first surface, at least some of said bulbous surface aberrations having an end portion and base portion, wherein said end portion comprises at least one microbubble substantially coinciding with the point of maximum amplitude of said bulbous surface aberration, and said microbubble and said base portion of said bulbous surface aberration each have opposed walls separated by an intervening space;   (b) coating a pressure-sensitive adhesive layer over at least a portion of the surface of at least some of said bulbous surface aberrations; and   (c) bonding said pressure-sensitive adhesive layer to said backing web.   
     
     
       2. The method of claim 1 wherein said pressure-sensitive adhesive is coated over the entire surface of at least some of said bulbous surface aberrations. 
     
     
       3. The method of claim 2 wherein said pressure-sensitive adhesive layer is additionally coated over said first surface of said backing web. 
     
     
       4. The method of claim 3 wherein said pressure-sensitive adhesive layer is uniformly coated over said first surface of said backing web. 
     
     
       5. The method of claim 3 wherein the step (b) of coating adhesive comprises: applying a unmetered or partially metered amount of pressure-sensitive adhesive into said backing web, and removing any excess adhesive so as to meter the final coat weight of adhesive on said backing web.   
     
     
       6. The method of claim 3 wherein the step (b) of coating adhesive comprises applying a predetermined volume of adhesive onto said backing web. 
     
     
       7. A method for forming a textured pressure-sensitive adhesive fastener, said method comprising the steps of: (a) providing a backing web of polymeric material, said backing web having a first surface and a second surface; continuously brining the backing web in contacting relation with a continuous, moving forming member exhibiting a pattern of bulbous apertures extending from the outermost to the innermost surface of said forming member; contacting the second surface of said backing web with a resiliently deformable roll having a multiplicity of liquid-filled capillary networks about its periphery while said backing web is supported on said forming member; and   applying sufficient force between said forming member and said resiliently deformable roll to at least partially collapse said liquid-filled capillary network on said resiliently deformable roll, thereby causing the liquid contained therein to permanently deform said backing web towards said forming member without rupturing said backing web such that said backing web acquires a pattern of bulbous surface aberrations substantially coinciding with the image of the pattern of apertures in said forming member due to the hydraulic pressure exerted by the liquid contained in said capillary networks, so that at least some of said bulbous surface aberrations have an end portion and base portion, wherein said end portion comprises at least one microbubble substantially coinciding with the point of maximum amplitude of said bulbous surface aberration, and said microbubble and said base portion of said bulbous surface aberration each have opposed walls separated by an intervening space;     (b) coating a pressure-sensitive adhesive layer over at least a portion of the surface of at least some of said bulbous surface aberrations of said backing web; and   (c) bonding said pressure-sensitive adhesive layer to said backing web.   
     
     
       8. The method of claim 7 additionally comprising the step of corona-treating said backing web of polymeric material prior to applying the pressure-sensitive adhesive layer over said backing web so as to make said backing web wettable by the pressure-sensitive adhesive. 
     
     
       9. A method for forming a textured pressure-sensitive adhesive fastener, said method comprising the steps of: (a) providing a backing web having a first surface and a second surface, the backing web having discrete, bulbous surface aberrations projecting from the first surface, at least some of said bulbous surface aberrations having an end portion and base portion, wherein said end portion comprises at least one microbubble substantially coinciding with the point of maximum amplitude of said bulbous surface aberration, and said microbubble and said base portion of said bulbous surface aberration each have opposed walls separated by an intervening space, said microbubble comprising a flexible membrane joined about its periphery to said base portion, said walls of said microbubble thinner than the walls of said base portion of said bulbous surface aberration;   (b) coating a pressure-sensitive adhesive layer over at least a portion of the surface of at least some of said bulbous surface aberrations; and   (c) bonding said pressure-sensitive adhesive layer to said backing web.